2004-2008 Ford E-Series Cooling System – Fuel Contamination Diagnostics

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Filed Under (Ford) by admin on 04-05-2011

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6.0L DIESEL FUEL IN ENGINE COOLANT DIAGNOSTICS FORD: 2003-2005 Excursion 2003-2007 F-Super Duty 2004-2008 E-Series ISSUE Some 2003-2005 Excursion, 2003-2007 F-Super Duty and 2004-2008 E-Series vehicles equipped with a 6.OL engine may exhibit fuel in the engine coolant, due to leaks in the cylinder head fuel injector area. Symptoms may include fuel in engine coolant and coolant expulsion from the degas bottle. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Inspect the degas bottle for evidence of fuel in engine coolant. If diesel fuel is present, refer to the following Service Procedure. If not, follow normal diagnostics. NOTE IT IS VERY IMPORTANT TO ENSURE A COMPLETE FLUSHING OF THE ENGINE COOLING SYSTEM IS PERFORMED TO REMOVE ALL CONTAMINANTS FOLLOWING REPAIR. 1. Drain coolant from cooling system. 2. Remove all injectors from both cylinder heads. Refer to Workshop Manual (WSM), Section 313-04C. 3. Wipe injector bore clean of oil and fuel then apply a thin layer of bubbly type liquid hand soap, dish soap or laundry soap inside each injector bore. Ensure injector sleeve lip and cylinder head casting are coated with a soap layer. (Adding a small amount of water to the soap aids in creating bubbles) 4. Fit the cooling system pressure tester, refer to WSM, Section 303-03. (Do not add coolant) 5. Apply 5-10 psi (34-69 kPa) of air pressure to sealed cooling system. It is suggested to use a hand operated pressure tester or regulated shop air with tee in degas hose to degas bottle. NOTE MORE THAN 10 PSI (69 kPa) AIR PRESSURE CAN PUSH THE SOAP FROM THE LEAK POINT AND NO BUBBLES WILL BE PRESENT OR CREATED, MAKING DIAGNOSIS DIFFICULT. 6. Inspect each injector bore for bubbles. (A light and mirror or bore-scope may aid in pinpointing a leak location.) If bubbles are observed, determine if bubbles originate from the injector sleeve lip (Figure 1) or cylinder head casting. (Figure 2) Refer to cutaway view of the cylinder head. (Figure 3) a. Replace the injector sleeve if found to be leaking at sleeve lip, refer to WSM 303-04C. b. Replace cylinder head if leaking through casting, refer to WSM 303-01C. c. Flush cooling system, refer to another applicable Technical Service Bulletin (TSB) for proper cooling system flush procedures.

2008-2010 Ford Escape Hybrid A/C – White Flakes Are Blowing From Dash Vents

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Filed Under (Ford) by admin on 30-04-2011

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LINCOLN: 2008-2010 Town Car 2000-2005 Navigator 2007-2009 MKX MERCURY: 2008-2010 Grand Marquis, Mariner Hybrid, Mariner This article supersedes TSB 9-19-16 to update the Service Procedure. ISSUE Some vehicles may experience white flakes coming from the A/C vents when the blower motor is engaged. This may be caused by flux utilized in the manufacturing process of the evaporator core. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Hazard and Risk Warnings for White Flakes WARNING MAY CAUSE EYE AND RESPIRATORY TRACT IRRITATION. PROLONGED REPEATED EXPOSURE MAY CAUSE BONE DAMAGE (FLUOROSIS) AND HARM TO THE RESPIRATORY SYSTEM (BASED ON ANIMAL DATA). ^ Avoid inhaling dust. ^ Avoid contact with eyes. ^ Store away from acids. ^ Wash thoroughly after handling. ^ Avoid release to the environment. NOTE THE USE OF DUST PROOF GOGGLES, CHEMICAL RESISTANT GLOVES (PVC) AND DUST MASK IS RECOMMENDED. Using compressed air (maximum inlet pressure) 100 PSI (689 kPa), clean the A/C ducts through the registers and blow off the evaporator core through the blower motor opening. NOTE THE ENTIRE EVAPORATOR CORE SURFACE MUST BE DRY FOR BEST RESULTS. NOTE WHILE PERFORMING THIS PROCEDURE AND SELECTING DIFFERENT VENT MODES SUCH AS FLOOR / PANEL AND FLOOR / DEFROST, IT MAY BE NECESSARY TO TEMPORARILY START THE ENGINE TO ENABLE MODE DOOR MOVEMENT. Clean A/C Ducts: 1. Remove floor duct trim. 2. Using masking tape, connect one end of the vacuum cleaner hose to the floor duct on driver side. 3. Tape closed all the other floor duct openings. 4. Obtain about two feet (61 cm) of rubber vacuum line large enough to fit the end of a small shop air blowgun. Secure the hose to the end of the blowgun using a worm clamp. 5. Close all instrument panel registers. 6. Set temperature setting to full cold. 7. Place mode in floor / panel. 8. Turn on vacuum cleaner. 9. Working with one register at a time insert the vacuum line down each duct and blow shop air through each duct for 30 seconds. Be sure to close each register before moving on to the next register. 10. Change mode to floor I defrost.

2004 Ford Freestar Intake Manifold Runner Control (IMRC) Actuator Removal and Installation

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Filed Under (Ford) by admin on 11-04-2011

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Removal and Installation 1. Disconnect the battery ground cable. For additional information, refer to Section 414-00. 2. Remove the parts in the order indicated in the following illustration and table. Item Part Number 1 14A464 2 14489 3 9F715 4 N806549-S 5 9J558 3. To install, reverse the removal procedure. Item 3: IMRC Actuator Rods Installation Note 1. New plastic actuator rod retainers must be installed any time the IMRC rods are disconnected. Item 5: IMRC Actuator Installation Note 1. Before installing the IMRC actuator, be sure to rotate the driver motor plate until the levers make contact with the set screws, then rotate the motor until the motor bracket bolt holes are aligned with the holes in the lower intake manifold. Description Camshaft position (CMP) sensor electrical connector (part of 12B637) Intake manifold runner control (IMRC) actuator electrical connector (part of 12B637) IMRC actuator rods (2 req’d) (part of 9J559) Installation Note IMRC actuator-to-intake manifold bolts (3 req’d) IMRC actuator Installation Note

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2000-2009 Ford Focus ENGINE VIBRATION AT IDLE

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Filed Under (Ford) by admin on 11-04-2011

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Some 2000-2009 Focus vehicles may exhibit an excessive engine vibration at idle, most noticeable when the transmission is engaged in reverse. This condition may be caused by small stones, road debris, ice or snow packed / lodged in the rear engine roll restrictor. ACTION: Inspect the rear engine roll restrictor for debris and install service shield if necessary. SERVICE PROCEDURE 1. 2. 3. 4. 5. Inspect the rear engine roll restrictor for debris. Remove any debris from rear engine roll restrictor. Remove the cross member-to-roll restrictor attachment bolt. Install service shield. (Figure 1) Install roll restrictor attachment bolt and torque to 35 lb-ft (47 N-m).

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2002 Ford F-150 Heater Core Removal and Installation

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Filed Under (Ford) by admin on 11-04-2011

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NOTE: If a heater core leak is suspected, the heater core must be pressure leak tested before it is removed from the vehicle. For additional information, refer to Section 412-00. 1. Drain the radiator. For additional information, refer to Section 303-03A. 2. Remove the instrument panel. For additional information, refer to Section 501-12. 3. Disconnect the heater core hose couplings. For additional information, refer to Section 412-00. 4. Remove the A/C plenum demister adapter. 1. Remove the screw. 2. Remove the A/C plenum demister adapter. 5. Remove the screws and position aside the relay bracket. 6. Disconnect the vacuum line. 7. Remove the plenum chamber top. 1. Remove the 15 screws. 2. Remove the plenum chamber top. 8. Remove the blend door assembly from the case. 9. Remove the heater core. 10. To install, reverse the removal procedure. Lubricate the coolant hoses with coolant hose lubricant or plain water only, if needed.

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